More precise inline coating thickness measurement solutions for coated films and foils

Vivek Komaragiri Sensory Analytics AIMCAL Technical Director Greensboro, NC USA

SENSORY ANALYTICS

2

Ruggedized optical interference technique

Coating thickness or Coat weight results

Lab and In-line system configurations Measurement of single or multiple layers Current thickness ranges: ~ 0.15 µ to 200 µ ~ 0.10 lbs/ream to 130 lbs/ream AIMCAL Technology of the Year: systems

Key features: New in-line measurement technology

Applications: Broad industrial utilization of technology

Medical Devices

Automotive Industry

Electronics

Metal Coils and Containers

Rigid Packaging

Window Films

Thin Films & Coatings

4

Overview: Alternate Technology

1. Beta/Gamma Nuclear gauging: Non-absolute measurement method Differential type of measurement technique Extra administrative burden Cannot measure thin coatings below 5 microns Cannot measure wet coating thickness

Cannot measure individual layer thickness

5

Overview: Alternate Optical Technologies

1. Reflectance Modeling: Non- Absolute measurement method Heavily dependent on theoretical modeling Will be affected by changes in coating or substrate properties Not fast enough for in-process plant use Extensive set-up time for new coatings

Difficult to setup for multi-layer coatings

6

Overview: Alternate Optical Technologies

2. Optical Absorption/ Transmission: Non- Absolute measurement method Depends on magnitude of absorption levels Limited wavelengths versus broad wavelength range Different wavelengths for different coatings

Not suitable for discrete layer measurements

Often supplied on same overdesigned frames

Overview: Exclusive SpecMetrix Optical Technologies

Proprietary ‘ruggedized optical interference’ technology Absolute thickness measurement results Substrate independent

Measures clear and opaque coatings Not affected by base color or printed substrate Scalable for off-line or In-process use for wet or dry coating measurement use Current range:0.15 to 250 micron thickness

8

Technical advantages: SpecMetrix Optical Methods

Discrete layer measurements Not a differential or total coat weight measurement method

Discrete film weights of single or dual layers can be measured

Absolute thickness measurements Highly precise and real-time measurement data.

No necessity to calibrate on supplied thickness/ weight standards Takes wet or dry in-process coating/layer measurements

Ability to monitor coatings immediately after application

Multiple probe and scanning configurations to meet QA needs Non-radioactive, non-contact and non-destructive method

Reduced administration and plant safety burdens

Continuous readings eliminate end-of-roll weight samples

Sample integrity maintained

Intrinsically safe for wet-end installations

9

Lab system: View of multiple layer film stack

Simultaneous measurement of multiple film and adhesive layers

Reflection is generated from each interface of multi-layer surfaces

Thickness peaks shown for individual layers and combination of layers

Suitable for adjacent layers with dissimilar refractive index values

Well-suited for ‘film weight forensics’ / QA review of finished film stack

10

Precise thickness and coat weight results:

nanometers mg/sq. inch microns gsm mils lbs/ream

Data Analysis: SpecMetrix technology outputs

Simple user and operator interfaces Requires minimal input from operator OPC, TCP/IP, PLC integration options

Management gets more reliable results:

- Automatic data recording and storage - No manual recording or data manipulation - Direct porting to SPC and QA systems

Gage R&R testing performed using NIST thickness standards Only gauge variability is tested

Performance: Customer Gage R&R Results

12

Performance: Measurement stability over time

Measurements taken on same sample daily for five days

High repeatability over a period of five days.

Product Days Layer1 Layer2 Layer3302398 Day1 1.630 3.250 6.750

Day2 1.610 3.310 6.750Day3 1.630 3.220 6.770Day4 1.650 3.180 6.800Day5 1.630 3.270 6.880

Standard Deviation 0.014 0.049 0.054

302386 Day1 1.590 3.240 6.850Day2 1.570 3.250 6.800Day3 1.560 3.240 6.840Day4 1.610 3.280 6.800Day5 1.570 3.250 6.800

Standard Deviation 0.020 0.016 0.025

302558-2 Day1 1.590 3.280 6.190Day2 1.470 3.360 6.220Day3 1.530 3.230 6.310Day4 1.550 3.300 6.200Day5 1.590 3.280 6.160

Standard Deviation 0.050 0.047 0.057

302558-2B Day1 1.560 3.200 6.110Day2 1.540 3.220 6.150Day3 1.540 3.210 6.160Day4 1.500 3.100 6.000Day5 1.510 3.220 6.170

Standard Deviation 0.024 0.051 0.070

13

Corporate Teams

QA Labs and sample testing R&D centers Film weight forensics/ Claim review Manufacturing Plants

QA work stations Incoming film roll inspection Pilot lines Coating/Laminating lines Coating and material suppliers In-process coating measurements

Range of Use: QA and Production

14

Scratch Resistant coatings – including UV Hard Coats

Adhesives: Solvent-based, Water-based, Pressure Sensitive

Coatings on Foils and metallized films

Solar Control and Specialty Films

TiO2 filled opaque base films

Barrier coatings including nano-barrier coatings

Optical enhancement coatings

Non-nuclear alternative for blown film measurement

Applications: Representative film & coating thickness

15

Applications: Expanding coated films opportunities

Transparent conductors

Flexible electronics

Thin film photovoltaics

Touch screen displays

Organic LEDs

Passive (nano) barrier films

Lubricious coatings & pretreatments

In-Process Benefits: Technology Impact on Production

Elimination of labor intensive and less accurate gauging

Optimized coating utilization and film weight distribution

Real-time adjustments can be made to in process coating application

Streamlined film weight checks and 1st piece inspections

Objective measurement data helps to eliminate operator error

Traceable quality certifications for each production run or coil

Reduced product rework and coating spoilage

Reduced new coating trial times and set-up times

Reductions in waste streams, solvent, coating and oven usage

Technology Implementation – Multi Channel Fixed

17

Technology Implementation – Scanning systems

18

Technology Implementation – Blown Film

19 Available as OEM accessory or as replacement to nuclear gauging

Technology Implementation – Multiple Coatings

20

21

Exclusive Coating Measurement Applications

Thickness measurement results on the following coatings

Adhesives on films and foils

Clear topcoats with similar coating/substrate

Opaque TiO2 base films

UV hardcoat on window films Nano Barrier coatings

Copyright Sensory Analytics LLC all rights reserved

22

Measurement Results - Adhesive on Foil Solvent based adhesive on foil

Typical wet coating thickness is measured around 7.5 microns.

Typical dry coating thickness around 2 microns.

Two probes used for simultaneous measurement on left and right

side of the roller.

23

Measurement Results - Clear top coat layers

Coating applied to facilitate printing on film substrates. Thin clear coated layer makes weigh strip weigh analysis difficult Material properties of coating are very similar to substrate making it difficult for other tools to measure. Measurements were performed in the wet state and dry coating thickness is accurately estimated based on percentage of solids.

Meas # Wet Thickness Estimated Dry Thicknesswet(µ) dry(µ)

1 2.87 0.862 2.91 0.873 2.88 0.864 2.85 0.865 2.95 0.89

AVERAGE 2.89 0.87

24

Performance: Correlation of wet (inline) to dry results

Average of wet and dry inline measurements over a period of time. Strong correlation between wet and dry measurements. Coating inspection possible in the wet state early in the process

Meas # Wet Thickness Dry Thicknesswet(µ) dry(µ) Correlation factor

1 18.20 3.75 4.852 21.66 4.45 4.873 22.20 4.52 4.91

Copyright Sensory Analytics LLC all rights reserved

25

Measurement Results – Acrylic on TiO2 base film Clear acrylic coating on opaque Tio2 filled white base film. Simultaneous measurement of two layers.

Acrylic TiO2thickness(μ) thickness(μ)

1 12.134 25.4342 12.235 25.3653 12.112 25.3894 12.127 25.4085 12.123 25.429

26

Measurement Results: Nano-barrier coatings

Protective barrier coatings applied to PET films for food applications

Coated films useful for printing and laminating uses

Coated layers are well below thickness range of traditional weight tools

Difficult to perform coat weight analysis without off-line layer removal gravimetric methods

Meas # Coating Thicknessdry(µ)

1 0.272 0.283 0.294 0.275 0.29

AVERAGE 0.28

27

Measurement Results: UV Hardcoats

Applied as a top most layer for a window film.

Functions as a scratch resistant layer.

Provides smooth finish to the product

Thickness range below the measurement range of conventional tools.

Very expensive coating.

Significant saving opportunities with tight control of applied coating.

Meas # Coating Thicknessdry(µ)

1 1.612 1.613 1.624 1.605 1.62

AVERAGE 1.61

New Opportunity: A Move to Thickness from Weights

Simple and absolute thickness measurement data now available

Simple and easy characterization for discrete layers

in multi-layer film applications

Move to single global uniform measurement unit

(currently Mg/in2, g/m2 Lbs./ream are all used)

One simple recipe used for multiple coatings

No dependence on accuracy of supplier coating data

Ability to accurately characterize difficult layers

Better means to properly study coating distribution

New Technology Offering:

Next Generation of In-line Measurement

New technology advancements to meet customer needs

New ultra thin In-line coating thickness measurement module

Minimum thickness limit for current optical configuration is ~ 150nm (0.15 microns)

Core ruggedized technologies are being expanded to measure ultra-thin coatings or layers ranging from 10 nanometers and above

Strong pre-interest from film industry leaders for measurement of:

Silicone Coatings

Coatings on Stretched films

High performance optical coatings

Overview: New optical technology for thinner coatings

Step 1: Unpolarized light from a light source is converted into polarized beam of light of know polarization state.

Overview: Principle of operation of new technology

Step 2: Linearly polarized light incident on the coated sample at an angle is reflected resulting in change in polarization and phase.

Technology is ruggedized for both lab and in-process measurements

Overview: Principle of operation of new technology

Step 3: Change in polarization and change in phase are evaluated from the reflected wave. Step 4: These parameters are used to calculate thickness of the coating with Angstrom level accuracy (1Angstrom ~ 1/10000th msi)

For additional information:

Questions?

The Sensory Building 4413 West Market Street

Greensboro, NC 27407 USA Tel: +1-336-315-6090

SENSORY ANALYTICS®

www.specmetrix.com

For system demos:

AIMCAL - Table Top Display